Composition

ABSTRACT

A pre-catalyzed urea-formaldehyde composition suitable for use in the manufacture of pressed particle board and laminated wood articles comprising an aqueous solution of about 20-21% by weight of urea and 50-51% of formaldehyde and 0.1 to 1.0% of a latent catalyst consisting essentially of a mixture of the hydrochloride salt of an amino alkanediol corresponding to the formula   WHERE R is methyl or ethyl, and an alkanolamine corresponding to the formula   WHERE R1 is hydrogen or alkyl of 1 or 2 carbon atoms, and R2 is hydrogen or methyl in a mole ratio of about 1.5-2.0 of the amino alkanediol per mole of alkanolamine.

United States Patent [191 Sausman [451 July 8,1975

[ COMPOSITION [75] Inventor: David K. Sausman, Terre Haute,

Ind.

[73] Assignee: Commercial Solvents Corporation,

Terre Haute, Ind.

[22] Filed: Oct. 113, 1970 [21] Appl. No.: 80,480

[52] US. Cl. 260/29.4 R; 260/69 R [51] Int. Cl. C08L 61/20 [58] Field of Search 260/29.4, 32.4, 33.4, 32.8 N,

[56] References Cited UNITED STATES PATENTS 2,485,485 10/1949 Dudley 260/70 R 2,795,513 6/1957 Rossin i 117/11 2,838,416 6/1958 Babiarz et a1 264/257 Primary Examiner-Joan E. Welcome Attorney, Agent, or Firm-Robert l-l. Dewey; Howard E. Post [57] ABSTRACT A pre-catalyzed urea-formaldehyde composition suitable for use in the manufacture of pressed particle l HOCH 2 c|:cH on where R is methyl or ethyl, and an alkanolamine corresponding to the formula a -c-cu oa where R is hydrogen or alkyl of 1 or 2 carbon atoms,

and R is hydrogen or methyl in a mole ratio of about 1.5-2.0 of the amino alkanediol per mole of alkanolamine.

8 Claims, No Drawings COMPOSITION BACKGROUND OF THE INVENTION This invention relates to improved ureaformaldehyde adhesives. In a particular aspect, this invention relates to improved urea-formaldehyde adhesives for the manufacture of laminated wood products, including particle or chip board.

Large amounts of urea-formaldehyde resins are used in the manufacture of laminated wood products, such as particle or chip board and plywood. These adhesives are usually prepared at the place of use by reacting formaldehyde and urea in the optimum proportions to produce a partially polymerized resin; for the manufacture of laminates, the resin is applied to the sheets to be laminated which are then assembled to form the article to be laminated and the whole is heated in a press, during which time the partially polymerized resin is completely polymerized, forming a strong bond be tween the wood surfaces and thereby forming the wood laminate. For the manufacture of particle or chip board, the adhesive is mixed thoroughly with the wood particles or chips and the mixture is then introduced into a press where it is heated under pressure.

Formaldehyde is usually shipped commercially as a 37% aqueous solution, but concentrations as high as 50% are common. Even at the highest concentration, considerable diluent-wateris being shipped at high freight rates. When the formaldehyde is intended for use in urea-formaldehyde adhesives, it is common practice to add urea to these solutions, not only to stabilize the formaldehyde against polymerization at reduced temperatures, but also to make it possible to reduce the water content and provide a higher payload. Mixtures containing 505l% formaldehyde with -2l% by weight urea and 29-30% water are common.

When the mixture is received at the place of use, sufficient additional urea is added to provide the optimum mole ratio, and the mixture is then heated (viz. the resin cook) to form the partially polymerized ureaformaldehyde resin which is then suitable for use as an adhesive.

This practice has been very successful, but the additional heating stepthe resin cookand the handling required significantly increase the costs of the process. Accordingly a need exists for an improved adhesive product.

SUMMARY OF THE INVENTION l uoca ccn OH I 2 NH where R is methyl or ethyl, and an alkanolamine corresponding to the formula where R is hydrogen or alkyl of l or 2 carbon atoms and R is hydrogen or methyl, in a mole ratio of about l.52.0 of the amino alkanediol per mole of alkanolamine.

The improved composition is particularly suitable for use as the adhesive in the manufacture of particle board and laminated wood articles and eliminates the resin cook heating step heretofore required. At the time of use, sufficient urea to provide a desirable mole ratio to formaldehyde, which ratio is known to those skilled in the art, is dissolved in the solution. During the manufacture of laminates, the resulting composition is applied directly without prior heating, to the surfaces of the components to be laminated or is mixed in suitable amounts with particles or chips. The components are then assembled, as is known, and heated in a press at an elevated temperature and pressure and for a length of time sufficient to produce the laminate.

For the manufacture of particle or chip board, the particles or chips are thoroughly mixed with the adhe sive in effective amounts in accordance with known methods. The mixture is then heated in a press at a temperature and at a pressure and for a length of time effective to produce the board.

DETAILED DESCRIPTION The precatalyzed urea-formaldehyde solution of the present invention is prepared by any suitable method, many of which are known. One suitable method is to dissolve gaseous formaldehyde from a formaldehyde generator, e.g. a methanol oxidation unit, in about an equal weight of a solution containing, for example, about water and 40% urea. To this is added catalytic amounts, e.g. from about 0.5 to 1.5% by weight, preferably O.8l%, of the latent catalyst herein described. This mixture has good shipping and storage properties. When ready for use, additional urea is dissolved therein to provide the optimum mole ratio of formaldehyde to urea, i.e. about 1.22:1, and the resulting mixture is suitable for use as a thermosetting adhesive without intermediate heating.

It is not intended that the catalyst be limited to any particular concentrations of formaldehyde and urea. The catalyst is effective over wide variations of concentrations.

The proportions of catalyst used in the composition of this invention can be varied within fairly broad limits as hereinbefore set forth. However, in the presence of relatively high proportions of catalyst, package stability becomes progressively poorer. In the presence of relatively low proportions of catalyst, the mixture will not polymerize satisfactorily in the press, thereby resulting in a poor bond. The amount of urea added before use also is important, as is known. Best results are obtained when the ratio is more than about 09:1 and less than about 2:l. As the ratio of urea is increased, the' hardness of the bonded adhesive increases, but package stability decreases. If either or both the catalyst and urea are decreased, weaker bonding results.

The latent catalyst can be provided by preparing a solution-usually, but not necessarily, aqueousof the amino alkanediol hydrochloride by known methods, e.g. by mixing the two components in equi-molar amounts, and adding thereto the alkanolamine in a mole ratio of about 1.5-2.0 sufficient to provide a pH of within about 7.5-8.0.

The amino alkanediols suitable for the preparation of the latent catalyst include, but are not limited to, 2-

amino-2-methyll ,3-propanediol and preferably 2- amino-2-ethyl-l ,3-propanediol because it generally gives a faster cure. Otheramino alkanediols can also be used and they are regarded as obvious equivalents of i the preferred compounds. Mixtures of amino alkanediols are also suitable for the practice of this invention. Products of good quality are generally preferred.

The alkanolamines suitable for the compositions of the present invention include, but are not limited to, monoethanolamine, 2-amino-2-methyl-l-propanol, 2-

amino-.l-butanol and the N,N-dimethyl derivatives of these: compounds, as well as mixtures thereof. Other primary and tertiary alkanolamines can also be usedand are regarded as obvious equivalents of the preferred alkanolamines. The preferred alkanolamine is 2 -amino-2-methyl-l-propanol. Products of good quality are preferred to avoid color development during the baking step. The term alkanolamine as used here is intended to mean mono-amino, monohydroxy substituted alkanes. The amino substituent can also be substituted with alkyl, e.g. methyl, groups.

A suitable and convenient catalyst which is available commercially is Adamac Catalyst 20, marketed by McWhorter Chemical Co., 1645 So. Kilbourn Avenue, Chicago, Illinois, 60623. This productis a nearly-non aqueous solution at about 20% by weight catalyst. When used in the practice of the present invention, it is employed at about 45% based on the weight of the urea-formaldehyde solution, thereby providing the preferred concentration of 0.8-1 .0% as set forth hereinbefore.

The temperatures and pressures used in forming the laminates and particle board are generally those known and used in the art, e.g. from about 200 to about 300 psig at from about 250 to 350F. Dwell time'in the press is' determined by the thickness of the laminate or particle board. For example about 3 /2 min. for inch board to about 5 min. for /1 inch board is generally sufficient.

The invention will bebetter understood with reference to' the following examples. It is understood how ever that the examples are for illustration only, and it is not intended that the invention be limited thereby.

' EXAMPLE 1 lowing composition:

4 2-Amino-2-ethyl-l.3-propanediol hydrochloride 1 l l parts 2-Amino-2-mcthyl-l-propanol 1 3 r 35 lsobutyl alcohol 567.5 Water r q ,i a 44 20%i late nt catalyst solids, the Adamac 20 provided catalyst concentrations of 0.2, 0.4, 0.6, 0.8 and 1.0% respectively. Themixtures were divided into 2 EXAMPLE 2 I To two portions of 100 parts each of the ureaformaldehyde solution of Example 1 there were added 5 parts and 10 parts respectively of Adamac Catalyst 20, thus'providing latent catalyst concentrations of approximately l% and 2% respectively. Another portion of urea-formaldehyde solution without catalyst was used as a control. These portions were designated 2, 3 and] respectively.

vEach of the above samples was divided into three portions which were designated la, lb, 10; 2a, 2b, 2c; and 3a, 3b and 3c respectively. To each of the a samples there was added sufficient urea to provide a mole ratio of formaldehydezurea of 0.91; to each of the b samples was added sufficient urea to provide a mole ratio of 122;- and to each of the 0 samples was added sufficient urea to provide a mole ratio of 2.

To a portion, 20 parts, of each of the above 9 samples was added 6 parts of wood flour and a slurry was formed. The slurry was cast into 6 inch plaques which were then baked at 275F for 30 minutes. All of the catalyzed samples cured well. At a mole ratio of formaldehyde:urea of 0.91 the most rigid plaque was produced whereas at a mole ratio of 2, the plaques were crumbly and semi-soft. 7

EXAMPLE 3 The nine'mixtures prepared-in Example 2 were further tested for preparing fir laminates. Strips of fir 5 inchesXl inch$ inch were prepared and three strips were laminated by placing 1 ml of each ureaformaldehyde solution between each contacting surface. Each of the assembled articles was sealed in foil and laminated in a press at 250F and 200 psig for 30 minutes. After 1 hour, the laminate was tested for satisfactory cure and water resistance. v I

The laminates were prepared in duplicate. One set was placed in boiling water for 1 hour after removing from the press, and the other set was allowed to age 1 hour at room temperature,Thestrength of the laminate was then tested by wedging a scalpel at the Fir strip interfaces and attempting to pry apart. Wood failure was reported as pass. Adhesive failure was reported as approximate surface area which failed. The results are summed up in the following table.

Laminate Sample Catalyst Mole Ratio Stability 1 Hour in H O No. 71 Wt. HCHO/Urea Hours 1 Hour at 100C 1a 0.91 96 Pass 1b 0 1.22 50% Fail 1c 0 Z 60% Fail 2a 1 0.91 2 Pass 30% Fail 2b 1 1.22 3 Pass Pass 2c 1 2 168 50% Fail Pass 3a 2 0.91 1% Pass Pass D 313 2 1.22 2% Pass Pass 3c 2 2 168 Pass 70% Fail EXAMPLE 4 prepared as described in Example 1, was spread. The

assembled strips were then heated in a press at 300F 2$313 32??? i a iil piieifiii fi i iiiiififi ii and varying Periods time 3 tuted for isobutyl alcohol. The resulting catalyst comto stresgs igtended to z Se aration at lued 'l position is incorporated in ureaformaldehyde solution. From these tests it was deterlfnined that g31/2 i The solution has a satisfactory shelf life, and when adheating time was optimum for the 4-ply laminates and ditional urea is dissolved therein and applied to an artif f h 6 l cle and heated, it cures rapidly. We mmutes was Optlmum or t e p EVAMPLE 5 EXAMPLE 11 A The experiment of Example 4 is repeated except that g gf gfgz g gssfz ii i zgj iy siii Examzamino-l'butanol is Substituted for Zamino'zmethyl cfsitioi i of tl ie adhesive wai v aried hoiv ei/er as f o fli ii l-propanol. The resulting composition has good shelf p 1 1 Th f M d life, and when additional urea is added and the compoampfe ggg g y 8 1O H175 sition is used to laminate articles, it cures rapidly at ele- Con i a j, 0 Ca 8 ys Concen r8 e Vamd temperatures cloud time, or pot life of the catalyzed adhesive mixture is about 2.5 hours at 7075F.

F I P TXAM LE 6 EXAMPLE 12 The experiment of Example 4 is repeated except that monoethanolamine is substituted for 2-amino-2- U,Smg the catalyst of Example 1 a conceniranon of methyl l propanol The resulting Composition has 1% in the urea-formaldehyde solution, and using a torgood shelf life, and when additional urea is added and g gb to s d 23 a p s i gg the composition is used to laminate articles, it cures prepare y mlxmg, 0 ywelg t erapidly at elevated temperatures. sive with ground wood particles. The mixture is then placed in a press at 250 psig and heated for 3.5 minutes EXAMPLE 7 at 300F. A durable pressed board is thereby obtained. The experiment or" Example 4 is repeated except that What clalmed 1S: N,N-dimethyl-2-amino-2-methyl-l-propanol is substiprecafialyzed aqueous llrea'formaldehyde tuted for 2amino2-methyl-lpropanol. The resulting posmon Conslstmg by welght 50-51% formalde' composition has good shelf life, and when additional hyde 20-21% F Water and about Ofa urea is added and the composition is used to laminate Catalyst F 0f the hydrochlonde Salt of an articles, it cures rapidly at elevated temperatures. ammo alkanedlol Correspondmg to the formula EXAMPLE 8 The experiment of Example 4 is repeated except that HOCH CCH OH NJl-dimethyl-Z-amino-l-butanol is substituted for 2-amino-2-niethyl-l-propanol. The resulting composition has good shelf life, and when additional urea is added and the composition is used to laminate articles, where R is methyl or ethyl, and an alkanolamine correit cures rapidly at elevated temperatures. sponding to the formula EXAMPLE 9 2 The experiment of Example 4 is repeated except that N,N-dimethyl-monoethanolamine is substituted for c Z-amino-Z-methyl-l-propanol. The resulting composi- 2. tion has good shelf life, and when additional urea is N( R added and the composition is used to laminate articles, it cures rapidly at elevated temperatures. I

where R is hydrogen or alkyl of 1 or 2 carbon atoms, EXAMPLE 1O and R is hydrogen or methyl in a mole ratio of about in this example, 4-ply and 6-ply laminates were prepared from 1 inch 5 inchesX fli inch fir strips. The strips were assembled so that the end of alternate strips extended 1/16 inch beyond the end of the adjoining strip. Between each pair of strips, 0.5 ml of adhesive,

1.52.0 of the amino alltanediol per mole of alkanolamine.

2. The composition of claim 11 wherein said latent catalyst is present in a concentration of about 0.8 to 1.0% by weight.

3. The composition of claim 1 wherein said ami: noalkanediol is 2-amino-2-methyl-l ,3-propanediol.

4. The composition of claim 1 wherein said ami noalkanediol is 2-amino-2-ethyl-l ,3-propanediol.

' 5. The composition of claim 1 wherein said alkanola -5 mine is Z-amino- 1 -ethanol.

6. The composition of claim 1 wherein said alkanola inine is N,N-dimethyl-Z-amino-2-methyll -propahol. 

1. A PRE-CATALYZED AQUEOUS UREA-FORMALDEHYDE COMPOSITION CONSISTING OF, BY WEIGHT, 50-51% FORMALDEHYDE, 20-21% UREA, WATER AND ABOUT 0.5-1.5% OF A LATENT CATALYST MIXTURE OF THE HYDROCHLORIDE SALT OF AN AMINO ALKANEDIOL CORRESPONDING TO THE FORMULA
 2. The composition of claim 1 wherein said latent catalyst is present in a concentration of about 0.8 to 1.0% by weight.
 3. The composition of claim 1 wherein said aminoalkanediol is 2-amino-2-methyl-1,3-propanediol.
 4. The composition of claim 1 wherein said aminoalkanediol is 2-amino-2-ethyl-1,3-propanediol.
 5. The composition of claim 1 wherein said alkanolamine is 2-amino-1-ethanol.
 6. The composition of claim 1 wherein said alkanolamine is 2-amino-2-methyl-1-propanol.
 7. The composition of claim 1 wherein said alkanolamine is 2-amino-1-butanol.
 8. The composition of claim 1 wherein said alkanolamine is N,N-dimethyl-2-amino-2-methyl-1-propanol. 